Flexible Keypad Button/s in Nylon

thingiverse

Large systems I design often feature multiple keypads, typically with a main interface and smaller units for minor mechanical adjustments or calibration. As keypads are usually die-cut and tooled, prototypes can be expensive. 3D printing flexible keypads allows for faster, more cost-effective prototyping and accurate form, fit, and function evaluation. To achieve this, the .stl file is "step-and-repeated" in a pattern, Boolean added to a rectangle or box, rotated so buttons are on a side wall, then printed as a hollow part. A .4mm nozzle and .12mm layers work well; print at 1 perimeter and 2 solid layers for strength. Stop printing when the desired height is reached, cut off the key-containing side with scissors, and trim to desired shape. Nylon's flexibility and lack of delamination make for durable keypads. Designs can incorporate various button sizes, using a single nylon layer and an "S" joint for flexibility. A .dxf file with the profile is provided for assistance. An upcoming project involves printing on a tubular curve for a customer who wants a tubular-shaped keypad with a rocker thumb switch and two directional switches mounted on an activation handle. The material can be found at taulman3D.com.